PART QW WELDING

ARTICLE I
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WELDING GENERAL REQUIREMENTS

QW-100 GENERAL Article II for each process to be used in production weld-

ing. In addition, when other Sections of the Code require
Section IX of the ASME Boiler and Pressure Vessel notch toughness qualification of the WPS, the applicable
Code relates to the qualification of welders, welding oper- supplementary essential variables must be addressed in
ators, brazers, and brazing operators, and the procedures the WPS.
that they employ in welding and brazing according to the The purpose for qualification of a WPS is to determine
ASME Boiler and Pressure Vessel Code and the ASME that the weldment proposed for construction is capable
B31 Code for Pressure Piping. It is divided into two parts: of providing the required properties for its intended appli-
Part QW gives requirements for welding and Part QB cation. Welding procedure qualification establishes the
contains requirements for brazing. Other Sections of the properties of the weldment, not the skill of the welder or
Code may specify different requirements than those speci- welding operator.
fied by this Section. Such requirements take precedence The Procedure Qualification Record (PQR) documents
over those of this Section, and the manufacturer or con- what occurred during welding the test coupon and the
tractor shall comply with them. results of testing of the coupon. As a minimum, the PQR
QW-100.1 A Welding Procedure Specification shall document the essential variables and other specific
(WPS) is a written document that provides direction to information identified in Article II for each process used
the welder or welding operator for making production during welding the test coupon and the results of the
welds in accordance with Code requirements. Any WPSs required testing. In addition, when notch toughness test-
used by a manufacturer or contractor that will have ing is required for procedure qualification, the applicable
responsible operational control of production welding supplementary essential variables for each process shall
shall be a WPS that has been qualified by that manufac- be recorded.
turer or contractor in accordance with Article II, or it shall QW-100.2 In performance qualification, the basic cri-
be an AWS Standard Welding Procedure Specification terion established for welder qualification is to determine
(SWPS) listed in Appendix E and adopted by that manu- the welder’s ability to deposit sound weld metal. The
facturer or contractor in accordance with Article V. purpose of the performance qualification test for the weld-
Both WPSs and SWPSs specify the conditions (includ- ing operator is to determine the welding operator’s
ing ranges, if any) under which welding must be per- mechanical ability to operate the welding equipment.
formed. These conditions include the base metals that are
permitted, the filler metals that must be used (if any), QW-100.3 Welding Procedure Specifications (WPS)
preheat and postweld heat treatment requirements, etc. written and qualified in accordance with the rules of this
Such conditions are referred to in this Section as welding Section, and welders and welding operators of automatic
“variables.” and machine welding equipment also qualified in accor-
When a WPS is to be prepared by the manufacturer dance with these rules may be used in any construction
or contractor, it must address, as a minimum, the specific built to the requirements of the ASME Boiler and Pressure
variables, both essential and nonessential, as provided in Vessel Code or the ASME B31 Code for Pressure Piping.

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 QW-100.3 2004 SECTION IX QW-122.3

However, other Sections of the Code state the condi- to qualify the welding procedures he uses in the construc-
tions under which Section IX requirements are manda- tion of the weldments built under this Code, and the
tory, in whole or in part, and give additional requirements. performance of welders and welding operators who apply
The reader is advised to take these provisions into consid- these procedures.
eration when using this Section. QW-103.2 Records. Each manufacturer or contractor
Welding Procedure Specifications, Procedure Qualifi- shall maintain a record of the results obtained in welding
cation Records, and Welder/Welding Operator Perform- procedure and welder and welding operator performance
ance Qualification made in accordance with the qualifications. These records shall be certified by the man-
requirements of the 1962 Edition or any later Edition of ufacturer or contractor and shall be accessible to the
Section IX may be used in any construction built to the Authorized Inspector. Refer to recommended Forms in
ASME Boiler and Pressure Vessel Code or the ASME Nonmandatory Appendix B.
B31 Code for Pressure Piping.
Welding Procedure Specifications, Procedure Qualifi- QW-110 WELD ORIENTATION
cation Records, and Welder/Welding Operator Perform-
ance Qualification made in accordance with the The orientations of welds are illustrated in figure QW-
requirements of the Editions of Section IX prior to 1962, 461.1 or figure QW-461.2.
in which all of the requirements of the 1962 Edition or
later Editions are met, may also be used. QW-120 TEST POSITIONS FOR GROOVE
Welding Procedure Specifications and Welder/Weld- WELDS
ing Operator Performance Qualification records meeting Groove welds may be made in test coupons oriented
the above requirements do not need to be amended to in any of the positions in figure QW-461.3 or figure
include any variables required by later Editions and QW-461.4 and as described in the following paragraphs,
Addenda. except that an angular deviation of ±15 deg from the
Qualification of new Welding Procedure Specifications specified horizontal and vertical planes, and an angular
or Welders/Welding Operators and requalification of deviation of ±5 deg from the specified inclined plane are
existing Welding Procedure Specifications or Welders/ permitted during welding.
Welding Operators shall be in accordance with the current
Edition (see Foreword) and Addenda of Section IX. QW-121 Plate Positions
QW-121.1 Flat Position 1G. Plate in a horizontal
plane with the weld metal deposited from above. Refer
QW-101 Scope
to figure QW-461.3, illustration (a).
The rules in this Section apply to the preparation of QW-121.2 Horizontal Position 2G. Plate in a vertical
Welding Procedure Specifications and the qualification plane with the axis of the weld horizontal. Refer to figure
of welding procedures, welders, and welding operators QW-461.3, illustration (b).
for all types of manual and machine welding processes

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QW-121.3 Vertical Position 3G. Plate in a vertical
permitted in this Section. These rules may also be applied,
plane with the axis of the weld vertical. Refer to figure
insofar as they are applicable, to other manual or machine
QW-461.3, illustration (c).
welding processes permitted in other Sections.
QW-121.4 Overhead Position 4G. Plate in a hori-
zontal plane with the weld metal deposited from under-
QW-102 Terms and Definitions neath. Refer to figure QW-461.3, illustration (d).
Some of the more common terms relating to welding
and brazing are defined in QW/QB-492. QW-122 Pipe Positions
Wherever the word pipe is designated, tube shall also QW-122.1 Flat Position 1G. Pipe with its axis hori-
be applicable. zontal and rolled during welding so that the weld metal
is deposited from above. Refer to figure QW-461.4, illus-
tration (a).
QW-103 Responsibility
QW-122.2 Horizontal Position 2G. Pipe with its axis
QW-103.1 Welding. Each manufacturer1 or contrac-
vertical and the axis of the weld in a horizontal plane.
tor1 is responsible for the welding done by his organiza-
Pipe shall not be rotated during welding. Refer to figure
tion and shall conduct the tests required in this Section QW-461.4, illustration (b).
1
Wherever these words are used in Section IX, they shall include QW-122.3 Multiple Position 5G. Pipe with its axis
installer or assembler. horizontal and with the welding groove in a vertical plane.

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 QW-122.3 WELDING GENERAL REQUIREMENTS QW-141.5

Welding shall be done without rotating the pipe. Refer QW-132.2 Horizontal Positions 2F and 2FR
to figure QW-461.4, illustration (c). (a) Position 2F. Pipe with its axis vertical so that the
QW-122.4 Multiple Position 6G. Pipe with its axis weld is deposited on the upper side of the horizontal
inclined at 45 deg to horizontal. Welding shall be done surface and against the vertical surface. The axis of the
without rotating the pipe. Refer to figure QW-461.4, illus- weld will be horizontal and the pipe is not to be rotated
tration (d). during welding. Refer to figure QW-461.6, illustration
(b).
(b) Position 2FR. Pipe with its axis horizontal and the
QW-123 Test Positions for Stud Welds axis of the deposited weld in the vertical plane. The pipe
QW-123.1 Stud Welding. Stud welds may be made is rotated during welding. Refer to figure QW-461.6,
in test coupons oriented in any of the positions as illustration (c).
described in QW-121 for plate and QW-122 for pipe
(excluding QW-122.1). In all cases, the stud shall be QW-132.3 Overhead Position 4F. Pipe with its axis
perpendicular to the surface of the plate or pipe. See vertical so that the weld is deposited on the underside of
figures QW-461.7 and QW-461.8. the horizontal surface and against the vertical surface.
The axis of the weld will be horizontal and the pipe is
not to be rotated during welding. Refer to figure QW-
QW-130 TEST POSITIONS FOR FILLET 461.6, illustration (d).
WELDS QW-132.4 Multiple Position 5F. Pipe with its axis
Fillet welds may be made in test coupons oriented in horizontal and the axis of the deposited weld in the verti-
any of the positions of figure QW-461.5 or figure QW- cal plane. The pipe is not to be rotated during welding.
461.6, and as described in the following paragraphs, Refer to figure QW-461.6, illustration (e).
except that an angular deviation of ±15 deg from the
specified horizontal and vertical planes is permitted dur-
ing welding. QW-140 TYPES AND PURPOSES OF TESTS
AND EXAMINATIONS
QW-131 Plate Positions QW-141 Mechanical Tests
QW-131.1 Flat Position 1F. Plates so placed that the
weld is deposited with its axis horizontal and its throat Mechanical tests used in procedure or performance
vertical. Refer to figure QW-461.5, illustration (a). qualification are specified in QW-141.1 through QW-
141.5.
QW-131.2 Horizontal Position 2F. Plates so placed
that the weld is deposited with its axis horizontal on the QW-141.1 Tension Tests. Tension tests as described
upper side of the horizontal surface and against the verti- in QW-150 are used to determine the ultimate strength
cal surface. Refer to figure QW-461.5, illustration (b). of groove-weld joints.
QW-131.3 Vertical Position 3F. Plates so placed that QW-141.2 Guided-Bend Tests. Guided-bend tests as
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the weld is deposited with its axis vertical. Refer to figure described in QW-160 are used to determine the degree
QW-461.5, illustration (c). of soundness and ductility of groove-weld joints.
QW-131.4 Overhead Position 4F. Plates so placed QW-141.3 Fillet-Weld Tests. Tests as described in
that the weld is deposited with its axis horizontal on the QW-180 are used to determine the size, contour, and
underside of the horizontal surface and against the vertical degree of soundness of fillet welds.
surface. Refer to figure QW-461.5, illustration (d).
QW-141.4 Notch-Toughness Tests. Tests as
described in QW-171 and QW-172 are used to determine
QW-132 Pipe Positions
the notch toughness of the weldment.
QW-132.1 Flat Position 1F. Pipe with its axis
inclined at 45 deg to horizontal and rotated during welding QW-141.5 Stud-Weld Test. Deflection bend, ham-
so that the weld metal is deposited from above and at mering, torque, or tension tests as shown in figures QW-
the point of deposition the axis of the weld is horizontal 466.4, QW-466.5, and QW-466.6, and a macro-examina-
and the throat vertical. Refer to figure QW-461.6, illustra- tion performed in accordance with QW-202.5, respec-
tion (a). tively, are used to determine acceptability of stud welds.

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 QW-142 2004 SECTION IX QW-152

QW-142 Special Examinations for Welders thicknesses of pipe having an outside diameter greater
than 3 in. (75 mm).
Radiographic examination may be substituted for
(a) For thicknesses up to and including 1 in. (25 mm),
mechanical testing of QW-141 for groove-weld perform-
a full thickness specimen shall be used for each required
ance qualification as permitted in QW-304 to prove the
tension test.
ability of welders to make sound welds.
(b) For pipe thicknesses greater than 1 in. (25 mm),
full thickness specimens or multiple specimens may be
QW-143 Examination for Welding Operators used, provided QW-151.2(c) and QW-151.2(d) are com-
plied with.
An examination of a weld by radiography may be (c) When multiple specimens are used, in lieu of full
substituted for mechanical testing of QW-141 for groove thickness specimens, each set shall represent a single
weld performance qualification as permitted in QW-305 tension test of the full pipe thickness. Collectively, all of
to prove the ability of welding operators to make sound the specimens required to represent the full thickness of
welds. the weld at one location shall comprise a set.
(d) When multiple specimens are necessary, the entire
QW-144 Visual Examination thickness shall be mechanically cut into a minimum num-
ber of approximately equal strips of a size that can be
Visual examination as described in QW-194 is used tested in the available equipment. Each specimen of the
to determine that the final weld surfaces meet specified set shall be tested and meet the requirements of QW-153.
quality conditions. For pipe having an outside diameter of 3 in. (75 mm)
or less, reduced-section specimens conforming to the
requirements given in figure QW-462.1(c) may be used
QW-150 TENSION TESTS for tension tests.
QW-151 Specimens QW-151.3 Turned Specimens. Turned specimens
Tension test specimens shall conform to one of the conforming to the requirements given in figure QW-
types illustrated in figures QW-462.1(a) through QW- 462.1(d) may be used for tension tests.
462.1(e) and shall meet the requirements of QW-153. (a) For thicknesses up to and including 1 in. (25 mm),
a single turned specimen may be used for each required
QW-151.1 Reduced Section — Plate. Reduced-sec- tension test, which shall be a specimen of the largest
tion specimens conforming to the requirements given in diameter D of figure QW-462.1(d) possible for test cou-
figure QW-462.1(a) may be used for tension tests on all pon thickness [per Note (a) of figure QW-462.1(d)].
thicknesses of plate. (b) For thicknesses over 1 in. (25 mm), multiple speci-
(a) For thicknesses up to and including 1 in. (25 mm), mens shall be cut through the full thickness of the weld
a full thickness specimen shall be used for each required with their centers parallel to the metal surface and not
tension test. over 1 in. (25 mm) apart. The centers of the specimens
(b) For plate thickness greater than 1 in. (25 mm), full adjacent to the metal surfaces shall not exceed 5⁄8 in.
thickness specimens or multiple specimens may be used, (16 mm) from the surface.
provided QW-151.1(c) and QW-151.1(d) are complied (c) When multiple specimens are used, each set shall
with. represent a single required tension test. Collectively, all
(c) When multiple specimens are used, in lieu of full the specimens required to represent the full thickness of
thickness specimens, each set shall represent a single the weld at one location shall comprise a set.
tension test of the full plate thickness. Collectively, all (d) Each specimen of the set shall be tested and meet
of the specimens required to represent the full thickness the requirements of QW-153.
of the weld at one location shall comprise a set. QW-151.4 Full-Section Specimens for Pipe. Ten-
(d) When multiple specimens are necessary, the entire sion specimens conforming to the dimensions given in
thickness shall be mechanically cut into a minimum num- figure QW-462.1(e) may be used for testing pipe with an
ber of approximately equal strips of a size that can be outside diameter of 3 in. (75 mm) or less.
tested in the available equipment. Each specimen of the
set shall be tested and meet the requirements of QW-153. QW-152 Tension Test Procedure
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QW-151.2 Reduced Section — Pipe. Reduced-sec- The tension test specimen shall be ruptured under ten-
tion specimens conforming to the requirements given in sile load. The tensile strength shall be computed by divid-
figure QW-462.1(b) may be used for tension tests on all ing the ultimate total load by the least cross-sectional area

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 QW-152 WELDING GENERAL REQUIREMENTS QW-162.1

of the specimen as calculated from actual measurements specimens shall conform to the dimensions shown in
made before the load is applied. figure QW-462.2.
Specimens of base metal thickness equal to or greater
than 11⁄2 in. (38 mm) may be cut into approximately equal
QW-153 Acceptance Criteria — Tension Tests
strips between 3⁄4 in. (19 mm) and 11⁄2 in. (38 mm) wide
QW-153.1 Tensile Strength. Minimum values for for testing, or the specimens may be bent at full width
procedure qualification are provided under the column (see requirements on jig width in QW-466). If multiple
heading “Minimum Specified Tensile, ksi” of table QW/ specimens are used, one complete set shall be made for
QB-422. In order to pass the tension test, the specimen each required test. Each specimen shall be tested and
shall have a tensile strength that is not less than: meet the requirements in QW-163.
(a) the minimum specified tensile strength of the base
metal; or QW-161.2 Transverse Face Bend. The weld is trans-
(b) the minimum specified tensile strength of the verse to the longitudinal axis of the specimen, which is
weaker of the two, if base metals of different minimum bent so that the face surface becomes the convex surface
tensile strengths are used; or of the bent specimen. Transverse face-bend test speci-
(c) the minimum specified tensile strength of the weld mens shall conform to the dimensions shown in figure
metal when the applicable Section provides for the use QW-462.3(a). For subsize transverse face bends, see QW-
of weld metal having lower room temperature strength 161.4.
than the base metal; QW-161.3 Transverse Root Bend. The weld is trans-
(d) if the specimen breaks in the base metal outside verse to the longitudinal axis of the specimen, which is
of the weld or weld interface, the test shall be accepted bent so that the root surface becomes the convex surface
as meeting the requirements, provided the strength is of the bent specimen. Transverse root-bend test speci-
not more than 5% below the minimum specified tensile mens shall conform to the dimensions shown in figure
strength of the base metal. QW-462.3(a). For subsize transverse root bends, see QW-
(e) the specified minimum tensile strength is for full 161.4.
thickness specimens including cladding for Aluminum
QW-161.4 Subsize Transverse Face and Root
Alclad materials (P-No. 21 through P-No. 23) less than
1 Bends. See Note (2) of figure QW-462.3(a).
⁄2 in. (13 mm). For Aluminum Alclad materials 1⁄2 in.
(13 mm) and greater, the specified minimum tensile QW-161.5 Longitudinal-Bend Tests. Longitudinal-
strength is for both full thickness specimens that include bend tests may be used in lieu of the transverse side-bend,
cladding and specimens taken from the core. face-bend, and root-bend tests for testing weld metal or
base metal combinations, which differ markedly in bend-
ing properties between
QW-160 GUIDED-BEND TESTS (a) the two base metals; or
QW-161 Specimens (b) the weld metal and the base metal.

Guided-bend test specimens shall be prepared by cut- QW-161.6 Longitudinal Face Bend. The weld is par-
ting the test plate or pipe to form specimens of approxi- allel to the longitudinal axis of the specimen, which is
mately rectangular cross section. The cut surfaces shall bent so that the face surface becomes the convex surface
be designated the sides of the specimen. The other two of the bent specimen. Longitudinal face-bend test speci-
surfaces shall be called the face and root surfaces, the face mens shall conform to the dimensions shown in figure
surface having the greater width of weld. The specimen QW-462.3(b).
thickness and bend radius are shown in figures QW-466.1, QW-161.7 Longitudinal Root Bend. The weld is par-
QW-466.2, and QW-466.3. Guided-bend specimens are allel to the longitudinal axis of the specimen, which is
of five types, depending on whether the axis of the weld bent so that the root surface becomes the convex side of
is transverse or parallel to the longitudinal axis of the the bent specimen. Longitudinal root-bend test specimens
specimen, and which surface (side, face, or root) is on shall conform to the dimensions shown in figure QW-
the convex (outer) side of bent specimen. The five types 462.3(b).
are defined as follows.
A05 QW-161.1 Transverse Side Bend. The weld is trans- QW-162 Guided-Bend Test Procedure
verse to the longitudinal axis of the specimen, which is QW-162.1 Jigs. Guided-bend specimens shall be bent
bent so that one of the side surfaces becomes the convex in test jigs that are in substantial accordance with QW-
surface of the bent specimen. Transverse side-bend test 466. When using the jigs illustrated in figure QW-466.1

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QW-162.1 2004 SECTION IX QW-181.2

or figure QW-466.2, the side of the specimen turned orientation shall be as given in the Section requiring
toward the gap of the jig shall be the face for face-bend such tests.
specimens, the root for root-bend specimens, and the When qualifying pipe in the 5G or 6G position, the
side with the greater discontinuities, if any, for side-bend notch-toughness specimens shall be removed from the
specimens. The specimen shall be forced into the die by shaded portion of figure QW-463.1(f).
applying load on the plunger until the curvature of the
specimen is such that a 1⁄8 in. (3 mm) diameter wire cannot
QW-172 Notch-Toughness Tests — Drop Weight
be inserted between the specimen and the die of figure
QW-466.1, or the specimen is bottom ejected if the roller QW-172.1 General. Drop weight tests shall be made
type of jig (figure QW-466.2) is used. when required by other Sections.
When using the wrap around jig (figure QW-466.3), Test procedures and apparatus shall conform to the
the side of the specimen turned toward the roller shall requirements of ASTM Specification E 208.
be the face for face-bend specimens, the root for root-bend QW-172.2 Acceptance. The acceptance criteria shall
specimens, and the side with the greater discontinuities, if be in accordance with that Section requiring drop
any, for side-bend specimens. weight tests.
When specimens wider than 11⁄2 in. (38 mm) are to be
bent as permitted in figure QW-462.2, the test jig mandrel QW-172.3 Location and Orientation of Test Speci-
must be at least 1⁄4 in. (6 mm) wider than the specimen men. The drop weight test specimen, the crack starter
width. location, and the orientation shall be as given in the
Section requiring such tests.
When qualifying pipe in the 5G or 6G position, the
QW-163 Acceptance Criteria — Bend Tests notch-toughness specimens shall be removed from the
The weld and heat-affected zone of a transverse weld- shaded portion of figure QW-463.1(f).
bend specimen shall be completely within the bent portion
of the specimen after testing.
The guided-bend specimens shall have no open discon- QW-180 FILLET-WELD TESTS
tinuity in the weld or heat-affected zone exceeding 1⁄8 in. QW-181 Procedure and Performance
(3 mm), measured in any direction on the convex surface Qualification Specimens
of the specimen after bending. Open discontinuities QW-181.1 Procedure. The dimensions and prepara-
occurring on the corners of the specimen during testing tion of the fillet-weld test coupon for procedure qualifica-
shall not be considered unless there is definite evidence tion as required in QW-202 shall conform to the
that they result from lack of fusion, slag inclusions, or requirements in figure QW-462.4(a) or figure QW-
other internal discontinuities. For corrosion-resistant 462.4(d). The test coupon for plate-to-plate shall be cut
weld overlay cladding, no open discontinuity exceeding transversely to provide five test specimen sections, each
1
⁄16 in. (1.5 mm), measured in any direction, shall be approximately 2 in. (50 mm) long. For pipe-to-plate or
permitted in the cladding, and no open discontinuity pipe-to-pipe, the test coupon shall be cut transversely to
exceeding 1⁄8 in. (3 mm) shall be permitted along the provide four approximately equal test specimen sections.
approximate weld interface. The test specimens shall be macro-examined to the
requirements of QW-183.
QW-170 NOTCH-TOUGHNESS TESTS QW-181.1.1 Production Assembly Mockups.
Production assembly mockups may be used in lieu of
QW-171 Notch-Toughness Tests — Charpy
QW-181.1. The mockups for plate-to-shape shall be cut
V-Notch
transversely to provide five approximately equal test spec-
QW-171.1 General. Charpy V-notch impact tests imens not to exceed approximately 2 in. (50 mm) in
shall be made when required by other Sections. length. For pipe-to-shape mockups, the mockup shall be
Test procedures and apparatus shall conform to the cut transversely to provide four approximately equal test
requirements of SA-370. specimens. For small mockups, multiple mockups may
QW-171.2 Acceptance. The acceptance criteria shall be required to obtain the required number of test speci-
be in accordance with that Section specifying impact mens. The test specimens shall be macro-examined to
requirements. the requirements of QW-183.
QW-171.3 Location and Orientation of Test Speci- QW-181.2 Performance. The dimensions and the
men. The impact test specimen and notch location and preparation of the fillet-weld test coupon for performance

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 QW-181.2 WELDING GENERAL REQUIREMENTS QW-191.1

qualification shall conform to the requirements in figure QW-183 Macro-Examination — Procedure

QW-462.4(b) or figure QW-462.4(c). The test coupon for Specimens
plate-to-plate shall be cut transversely to provide a center
section approximately 4 in. (100 mm) long and two end One face of each cross section of the five test specimens
sections, each approximately 1 in. (25 mm) long. For in figure QW-462.4(a) or four test specimens in figure
pipe-to-plate or pipe-to-pipe, the test coupon shall be cut QW-462.4(d), as applicable shall be smoothed and etched
to provide two quarter sections test specimens opposite with a suitable etchant (see QW-470) to give a clear
to each other. One of the test specimens shall be fracture definition to the weld metal and heat affected zone. The
tested in accordance with QW-182 and the other macro- examination of the cross sections shall include only one
examined to the requirements of QW-184. When qualify- side of the test specimen at the area where the plate or
ing pipe-to-plate or pipe-to-pipe in the 5F position, the pipe is divided into sections i.e., adjacent faces at the cut
test specimens shall be removed as indicated in figure shall not be used. In order to pass the test
QW-463.2(h). (a) visual examination of the cross sections of the weld
metal and heat-affected zone shall show complete fusion
QW-181.2.1 Production Assembly Mockups. and freedom from cracks
Production assembly mockups may be used in lieu of the (b) there shall be not more than 1⁄8 in. (3 mm) difference
fillet-weld test coupon requirements of QW-181.2. in the length of the legs of the fillet
(a) Plate-to-shape
(1) The mockup for plate-to-shape shall be cut trans-
versely to provide three approximately equal test speci- QW-184 Macro-Examination — Performance
mens not to exceed approximately 2 in. (50 mm) in length. Specimens
The test specimen that contains the start and stop of the The cut end of one of the end plate sections, approxi-
weld shall be fracture tested in accordance with QW- mately 1 in. (25 mm) long, in figure QW-462.4(b) or the
182. A cut end of one of the remaining test specimens cut end of one of the pipe quarter sections in figure QW-
shall be macro-examined in accordance with QW-184. 462.4(c), as applicable, shall be smoothed and etched
(b) Pipe-to-shape with a suitable etchant (see QW-470) to give a clear
(1) The mockup for pipe-to-shape shall be cut trans- definition of the weld metal and heat affected zone. In
versely to provide two quarter sections approximately order to pass the test
opposite to each other. The test specimen that contains (a) visual examination of the cross section of the weld
the start and stop of the weld shall be fracture tested in metal and heat-affected zone shall show complete fusion
accordance with QW-182. A cut end of the other quarter and freedom from cracks, except that linear indications at
section shall be macro-examined in accordance with QW- the root not exceeding 1⁄32 in. (0.8 mm) shall be acceptable
184. When qualifying pipe-to-shape in the 5F position, (b) the weld shall not have a concavity or convexity
the fracture specimen shall be removed from the lower greater than 1⁄16 in. (1.5 mm)
90 deg section of the mockup. (c) there shall be not more than 1⁄8 in. (3 mm) difference
in the lengths of the legs of the fillet

QW-182 Fracture Tests

QW-190 OTHER TESTS AND
The stem of the 4 in. (100 mm) performance specimen EXAMINATIONS
center section in figure QW-462.4(b) or the stem of the
quarter section in figure QW-462.4(c), as applicable, shall QW-191 Radiographic Examination
be loaded laterally in such a way that the root of the weld QW-191.1 Method. The radiographic examination in A05
is in tension. The load shall be steadily increased until QW-142 for welders and in QW-143 for welding opera-
the specimen fractures or bends flat upon itself. tors shall meet the requirements of Article 2, Section V,
If the specimen fractures, the fractured surface shall except as follows:
show no evidence of cracks or incomplete root fusion, (a) A written radiographic examination procedure is
and the sum of the lengths of inclusions and porosity not required. Demonstration of density and image quality
visible on the fractured surface shall not exceed 3⁄8 in. requirements on production or technique radiographs
(10 mm) in figure QW-462.4(b) or 10% of the quarter shall be considered satisfactory evidence of compliance
section in figure QW-462.4(c). with Article 2 of Section V.

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 QW-191.1 2004 SECTION IX QW-192.3

(b) Final acceptance of radiographs shall be based on configurations. Rounded indications less than 1 ⁄3 2 in.
the ability to see the prescribed image and the specified (0.8 mm) in maximum diameter shall not be considered in
hole of a hole-type image quality indicator (IQI) or the the radiographic acceptance tests of welders and welding
designated wire of a wire-type IQI. The acceptance stan- operators in these ranges of material thicknesses.
dards of QW-191.2 shall be met.
QW-191.2 Radiographic Acceptance Criteria QW-191.2.3 Production Welds. The acceptance
standard for welding operators who qualify on production
QW-191.2.1 Terminology
welds shall be that specified in the referencing Code
(a) Linear Indications. Cracks, incomplete fusion,
Section. The acceptance standard for welders who qualify
inadequate penetration, and slag are represented on the
on production welds as permitted by QW-304.1 shall be
radiograph as linear indications in which the length is
per QW-191.2.2.
more than three times the width.
(b) Rounded Indications. Porosity and inclusions
such as slag or tungsten are represented on the radiograph QW-191.3 Record of Tests. The results of welder
as rounded indications with a length three times the width and welding operator performance tests by radiography
or less. These indications may be circular, elliptical, or shall be recorded in accordance with QW-301.4.
irregular in shape; may have tails; and may vary in
density.
QW-191.2.2 Acceptance Standards. Welder and
welding operator performance tests by radiography of QW-192 Stud-Weld Tests — Procedure
welds in test assemblies shall be judged unacceptable Qualification Specimens
when the radiograph exhibits any imperfections in excess
of the limits specified below. QW-192.1 Required Tests. Ten stud-weld tests are
(a) Linear Indications required to qualify each procedure. The equipment used
(1) any type of crack or zone of incomplete fusion for stud welding shall be completely automatic except
or penetration for manual starting.
(2) any elongated slag inclusion which has a length Every other welding stud (five joints) shall be tested
greater than either by hammering over until one-fourth of its length
(a) 1⁄8 in. (3 mm) for t up to 3⁄8 in. (10 mm), is flat on the test piece, or by bending the stud to an angle
inclusive of at least 15 deg and returning it to its original position
(b) 1⁄3t for t over 3⁄8 in. (10 mm) to 21⁄4 in. (57 mm), using a test jig and an adapter location dimension that
inclusive are in accordance with figure QW-466.4.
(c) 3⁄4 in. (19 mm) for t over 21⁄4 in. (57 mm) The remaining five welded stud joints shall be tested
(3) any group of slag inclusions in line that have in torque using a torque testing arrangement that is sub-
an aggregate length greater than t in a length of 12t, except stantially in accordance with figure QW-466.5. Alterna-
when the distance between the successive imperfections tively, where torquing is not feasible, tensile testing may
exceeds 6L where L is the length of the longest imperfec- be used, and the fixture for tensile testing shall be similar
tion in the group to that shown in figure QW-466.6, except that studs with-
(b) Rounded Indications out heads may be gripped on the unwelded end in the
(1) The maximum permissible dimension for jaws of the tensile testing machine.
rounded indications shall be 20% of t or 1⁄8 in. (3 mm),
whichever is smaller.
QW-192.2 Acceptance Criteria — Bend and Ham-
(2) For welds in material less than 1⁄8 in. (3 mm) in
mer Tests. In order to pass the test(s), each of the five
thickness, the maximum number of acceptable rounded
stud welds and heat-affected zones shall be free of visible
indications shall not exceed 12 in a 6 in. (150 mm) length
of weld. A proportionately fewer number of rounded separation or fracture after bending and return bending
indications shall be permitted in welds less than 6 in. or after hammering.
(150 mm) in length.
(3) For welds in material 1⁄8 in. (3 mm) or greater QW-192.3 Acceptance Criteria — Torque Tests. In
in thickness, the charts in Appendix I represent the maxi- order to pass the test(s), each of the five stud welds shall
mum acceptable types of rounded indications illustrated be subjected to the required torque shown in the following
in typically clustered, assorted, and randomly dispersed table before failure occurs.

8
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 QW-192.3 WELDING GENERAL REQUIREMENTS QW-195.2.1

Required Torque for Testing be based on the minor diameter of the threaded section
Threaded Carbon Steel Studs
of externally threaded studs, except where the shank
Nominal Diameter Threads /in. Testing Torque,
of Studs, in. (mm) and Series Designated ft-lb (J)
diameter is less than the minor diameter, or on the original
1
cross-sectional area where failure occurs in a non-
⁄4 (6.4) 28 UNF 5.0 (6.8)
1
⁄4 (6.4) 20 UNC 4.2 (5.7)
threaded, internally threaded, or reduced-diameter stud.
5
⁄16 (7.9) 24 UNF 9.5 (12.9) QW-192.4 Acceptance Criteria — Macro-Exami-
5
⁄16 (7.9) 18 UNC 8.6 (11.7) nation. In order to pass the macro-examination, each of
3
⁄8 (9.5) 24 UNF 17 (23.0) five sectioned stud welds and the heat-affected zone shall
3
⁄8 (9.5) 16 UNC 15 (20.3) be free of cracks when examined at 10X magnification,
7
⁄16 (11.1) 20 UNF 27 (36.6) which is required by QW-202.5 when studs are welded
7
⁄16 (11.1) 14 UNC 24 (32.5) to metals other than P-No. 1.
1
⁄2 (12.7) 20 UNF 42 (57.0)
1
⁄2 (12.7) 13 UNC 37 (50.2)
9
QW-193 Stud-Weld Tests — Performance
⁄16 (14.3) 18 UNF 60 (81.4)
9 Qualification Specimens
⁄16 (14.3) 12 UNC 54 (73.2)
5 QW-193.1 Required Tests. Five stud-weld tests are
⁄8 (15.9) 18 UNF 84 (114.0)
5
⁄8 (15.9) 11 UNC 74 (100.0)
required to qualify each stud-welding operator. The
3 equipment used for stud welding shall be completely
⁄4 (19.0) 16 UNF 147 (200.0)
3
⁄4 (19.0) 10 UNC 132 (180.0)
automatic except for manual starting. The performance
7 test shall be welded in accordance with a qualified WPS
⁄8 (22.2) 14 UNF 234 (320.0)
7
⁄8 (22.2) 9 UNC 212 (285.0)
per QW-301.2.
Each stud (five joints) shall be tested either by ham-
1 (25.4) 12 UNF 348 (470.0)
1 (25.4) 8 UNC 318 (430.0)
mering over until one-fourth of its length is flat on the
test piece or by bending the stud to an angle of at least
Required Torque for Testing 15 deg and returning it to its original position using a
Threaded Austenitic Stainless Steel Studs test jig and an adapter location dimension that are in
Nominal Diameter Threads /in. Testing Torque, accordance with figure QW-466.4.
of Studs, in. (mm) and Series Designated ft-lb (J)
1
⁄4 (6.4) 28 UNF 4.5 (6.1) QW-193.2 Acceptance Criteria — Bend and Ham-
1
⁄4 (6.4) 20 UNC 4.0 (5.4) mer Tests. In order to pass the test(s), each of the five
5
⁄16 (7.9) 24 UNF 9.0 (12.2) stud welds and heat affected zones shall be free of visible
5
⁄16 (7.9) 18 UNC 8.0 (10.8) separation or fracture after bending and return bending
or after hammering.

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3
⁄8 (9.5) 24 UNF 16.5 (22.4)
3
⁄8 (9.5) 16 UNC 14.5 (19.7)
7
⁄16 (11.1) 20 UNF 26.0 (35.3) QW-194 Visual Examination — Performance
7
⁄16 (11.1) 14 UNC 23.0 (31.2)
1
⁄2 (12.7) 20 UNF 40.0 (54.2) Performance test coupons shall show complete joint
1
⁄2 (12.7) 13 UNC 35.5 (48.1) penetration with complete fusion of weld metal and base
5
⁄8 (15.9) 18 UNF 80.00 (108.5) metal.
5
⁄8 (15.9) 11 UNC 71.00 (96.3)
3
⁄4 (19.0) 16 UNF 140.00 (189.8) QW-195 Liquid Penetrant Examination
3
⁄4 (19.0) 10 UNC 125.00 (169.5)
QW-195.1 The liquid penetrant examination in QW-
7
⁄8 (22.2) 14 UNF 223.00 (302.3) 214 for corrosion-resistant weld metal overlay shall meet
7
⁄8 (22.2) 9 UNC 202.00 (273.9)
the requirements of Section V, Article 6. The acceptance
1 (25.4) 14 UNF 339.00 (459.6) standards of QW-195.2 shall be met.
1 (25.4) 8 UNC 303.00 (410.8)
QW-195.2 Liquid Penetrant Acceptance Criteria
Alternatively, where torquing to destruction is not fea-
sible, tensile testing may be used. For carbon and austen- QW-195.2.1 Terminology
itic stainless steel studs, the failure strength shall be not relevant indications: indications with major dimensions
less than 35,000 psi (240 MPa) and 30,000 psi (210 MPa), greater than 1⁄16 in. (1.5 mm).
respectively. For other metals, the failure strength shall
not be less than 1 ⁄2 of the minimum specified tensile linear indications: an indication having a length greater
strength of the stud material. The failure strength shall than three times the width.

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 QW-195.2.1 2004 SECTION IX QW-198.1

rounded indications: an indication of circular or elliptical QW-462.10 and QW-462.11 for the appropriate material.
shape with the length equal to or less than three times Further, for each set, 90% shall have shear strength values
the width. between 0.9 and 1.1 times the set average value. The
QW-195.2.2 Acceptance Standards. Procedure remaining 10% shall lie between 0.8 and 1.2 times the
and performance tests examined by liquid penetrant tech- set average value.
niques shall be judged unacceptable when the examina- QW-196.2.2 Peel test specimens shall be prepared A05
tion exhibits any indication in excess of the limits as shown in figure QW-462.8.1 for spot and projection
specified below: welding and per figure QW-462.8.2 for seam welding.
(a) relevant linear indications The specimens shall be peeled or separated mechanically,
(b) relevant rounded indications greater than 3⁄16 in. and fracture shall occur in the base metal by tearing out
(5 mm) of the weld in order for the specimen to be acceptable.
(c) four or more relevant rounded indications in a line
separated by 1⁄16 in. (1.5 mm) or less (edge-to-edge) QW-197 Laser Beam Welding (LBW) Lap Joint
Tests — Procedure Qualification
Specimens
QW-196 Resistance Weld Testing QW-197.1 Required Tests. Six tension shear speci-
A05 QW-196.1 Metallographic Examination mens and eight macro specimens are required to qualify
QW-196.1.1 Welds shall be cross-sectioned, pol- each procedure. The qualification test coupon shall be
ished, and etched to reveal the weld metal. The section prepared in accordance with figure QW-464.1. The ten-
shall be examined at 10X magnification. Seam welding sion shear specimens shall conform to the dimensions
specimens shall be prepared as shown in figure QW- indicated in the table of figure QW-464.1. The longitudi-
462.7.3. The sectioned weldment shall be free of cracks, nal and traverse sections indicated in figure QW-464.1
incomplete penetration, expulsions, and inclusions. shall be cross-sectioned as closely as possible through
Porosity shall not exceed one void in the transverse cross the centerline of the weld. A minimum of 1 in. (25 mm)
section or three voids in the longitudinal cross section of shall be provided for examination of each longitudinal
a specimen. The maximum dimension of any void shall specimen. The traverse specimens shall be of sufficient
not exceed 10% of the thickness of the weld bead. length to include weld, the heat-affected zone, and por-
tions of the unaffected base material. Cross-sections shall
QW-196.1.2 For spot and seam welds, the mini- be smoothed and etched with a suitable etchant (see QW-
mum width of the weld nugget shall be as follows in 470), and examined at a minimum magnification of 25X.
relation to thickness, t, of the thinner member. The dimensions of the fusion zone and penetration of
Material Thickness, in. (mm) Weld Nugget Width each weld of the traverse specimens shall be measured
< 0.010 (0.25) 6t to the nearest hundredth of an inch and recorded.
≥ 0.010 (0.25) and < 0.020 (0.50) 5t QW-197.2 Acceptance Criteria — Tension Shear
≥ 0.020 (0.50) and < 0.040 (1.00) 4t
Tests. In order to pass the tension shear test(s), the
≥ 0.040 (1.00) and < 0.069 (1.75) 3t
≥ 0.069 (1.75) and < 0.100 (2.54) 2.50 t requirements of QW-153 shall apply.
≥ 0.100 (2.54) and < 0.118 (3.00) 2.25 t QW-197.3 Acceptance Criteria — Macro-Exami-
≥ 0.118 (3.00) and < 0.157 (4.00) 2t
nation. In order to pass the macro-examination, each of
≥ 0.157 (4.00) 1.80 t
the eight specimens shall meet the following criteria:
The weld depth (extent of fusion) shall be a minimum (a) The outline of the fusion zone shall be generally
of 20% of the thickness of the thinner ply (in each mem- consistent in size and regular in shape and uniformity of
ber) and a maximum of 80% of the total thickness of penetration.
all plies. (b) The examination of the weld area shall reveal
QW-196.1.3 For projection welds, the width of the sound weld metal, complete fusion along the bond line,
nugget shall be not less than 80% of the width of the and complete freedom from cracks in the weld metal and
projection. heat-affected zone.

QW-196.2 Mechanical Testing QW-198 Laser Beam Welding (LBW) Lap Joint
QW-196.2.1 Shear test specimens shall be prepared Tests — Performance Qualification
as shown on figure QW-462.9. For spot and projection Specimens
welds, each test specimen shall equal or exceed the mini- QW-198.1 Required Tests. A peel test specimen at
mum strength, and the average strength specified in tables least 6 in. (150 mm) long shall be prepared as shown in

10
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 QW-198.1 WELDING GENERAL REQUIREMENTS QW-199.2

figure QW-464.2 illustration (a) and macro specimens as cut along the axis of the pipe into an even number of
shown in figure QW-464.2 illustration (b). The peel test strips of a length sufficient to perform bend tests. The
specimens shall be peeled apart to destruction and the maximum width of each strip shall be 11⁄2 in. (38 mm)
fusion zone and penetration measured to the nearest hun- and the minimum width
dredth of an inch. The end of each strip of the macro
coupon shall be polished and etched to clearly reveal the w p t + D/4 for pipes NPS 2 (DN 50) and smaller
weld metal. The width and depth of penetration of each w p t + D/8 for pipes greater than NPS 2 (DN 50)
weld shall be measured to the nearest hundredth of an
where
inch. Each specimen shall be examined in accordance
with QW-197.1. D p OD of the tube
t p nominal wall thickness
QW-198.2 Acceptance Criteria — Peel Test and
Macro-Examination. In order to pass the peel test and w p width of the specimen
macro-examination, the dimensions of the fusion zone One edge of one strip from each coupon shall be pol-
(averaged) and the penetration (averaged) shall be within ished to a 600 grit finish with the final grinding parallel
the range of dimensions of those specified on the WPS to the long axis of the strip. The polished surface shall
that was used to make the test coupon. be examined at 5X magnification. No incomplete fusion
or other open flaws on the polished surface are acceptable.
QW-199 Flash Welding Defects occurring in the base metal not associated with
QW-199.1 Procedure Qualification Test Coupons the weld may be disregarded. For nontubular cross sec-
and Testing tions, four side-bend specimens shall be prepared from
QW-199.1.1 Test Coupon Preparation. For cou- the two remaining coupons as specified in figure QW-
pons NPS 1 (DN 25) and smaller, four test welds shall 462.2 and polished for examination.
be made, and for pipes over NPS 1 (DN 25), three test All flash shall be removed from the strips and the welds
coupons shall be made using one set of welding parame- shall be visually examined per QW-194. Half of the strips
ters (i.e., the same equipment, base metals, joint prepara- from each pipe specimen shall then be prepared as root
tion, and other essential variables to be utilized for bend specimens and the remaining strips shall be prepared
production welding.) These variables shall be recorded as face bend specimens in accordance with QW-160. The
on the qualification record. specimens shall be tested in accordance with QW-160,
except for the following:
A05 QW-199.1.2 Tensile Tests. For pipes NPS 1
(a) For P-No. 1, Groups 2 through 4 materials, the
(DN 25) and smaller, and nontubular cross sections, two
minimum bend radius (dimension B in figure QW-466.1)
full-section tensile specimens shall be prepared in accor-
shall be three times the thickness of the specimen.
dance with figure QW-462.1(e). For pipes greater than
NPS 1 (DN 25), two reduced section tension specimens (b) In lieu of QW-163, the sum of lengths of individual
shall be prepared in accordance with figure QW-462.1(b) open flaws on the convex surface of all the bend test
or figure QW-462.1(c) from one coupon. For nontubular specimens taken from each pipe individually shall not
cross sections, two reduced section tension specimens exceed 5% of the outside circumference of that test pipe.
shall be prepared in accordance with figure QW-462.1(a) QW-199.2 Flash Welding — Performance Qualifi-
or figure QW-462.1(d) from two of the coupons. The cation Test Coupons and Testing. One test coupon shall
specimens shall be tested in accordance with QW-150. be welded, cut into strips, visually examined, and bend
A05 QW-199.1.3 Section and Bend Testing. The entire tested in accordance with QW-197.3. Polishing and exam-
circumference of each remaining pipe coupon shall be ination of a cross-section is not required.
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 2004 SECTION IX

APPENDIX I
ROUNDED INDICATION CHARTS
(See QW-191.2)

Typical Quantity and Size Permitted

in 6 in. (150 mm) Length of Weld
1/ in. (3 mm) to 1/ in. (6 mm)
8 4
Thickness

Typical Quantity and Size Permitted

in 6 in. (150 mm) Length of Weld
Over 1/4 in. (6 mm) to 1/2 in. (13 mm)
Thickness

Typical Quantity and Size Permitted

in 6 in. (150 mm) Length of Weld
Over 1/2 in. (13 mm) to 1 in. (25 mm)
Thickness

Typical Quantity and Size Permitted

in 6 in. (150 mm) Length of Weld
Over 1 in. (25 mm) Thickness

12
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